Novel assembly key, door kits and methods of using the same

ABSTRACT

The present document describes a key for releasably connecting members at a right angle, furniture and door assembly kits comprising keys, and members having mating connectors along their ends for releasably connecting said members at a right angle through their mating connectors.

BACKGROUND

(a) Field

This invention relates to the field of building materials. More particularly, it relates to a key for releasably connecting members at a right angle, and to a door assembly kit comprising keys and members releasably connecting to form a door assembly.

(b) Related Prior Art

The assembly of building materials at a right angle is a challenging endeavour which is facilitated by specialized machinery and tools in industrial and manufacturing settings. However, such assembly remains difficult when performed in a household setting, especially by non-professional individuals.

When a customer purchases furniture or other household material, they may be provided unassembled or only partially assembled, and the assembly of such material usually involves fasteners (e.g. screws, nails, and the like), and adhesives (e.g. glues). The assembly of furniture or material may require other means of assembly which are not normally available to the end purchaser of the products due to their specialized nature. For example, typically, when a home is having its doors replaced, the replacement doors are available and/or delivered in already preformed or assembled forms. It is possible to purchase customized doors from specialized suppliers which will fabricate the door in their own workshop and deliver the product in assembled form, often with a preformed or semi-assembled frame ready to be installed in an opening in a structure. Furthermore, customizations normally involve preparation based on the custom size, depth or other parameters of the opening and rarely involve the mixing and matching of different components to provide unique door design as per the customer's specification.

As an example, U.S. Pat. No. 5,128,807 discloses a wooden door assembly having a wooden composite subframe and an insulative foam core encapsulated therein. However, the disclosed door is assembled from numerous members that are irreversibly put together and do not provide the convenience of allowing disassembly of the door after assembly.

For those disadvantages, there is still a need in the field of building material for ways of connecting members (parts) at a right angle in a releasable manner.

There is still a need in the field of building materials for door assembly kits.

SUMMARY

According to an embodiment, there is provided a key for releasably connecting a first and second member at a right angle which comprises:

-   -   a substantially elongated body to releasably connect the first         and second member at a right angle, the body having         -   a first mating connector on one end for releasably             connecting to a corresponding mating connector on the first             member; and         -   a second mating connector on a diametrically opposed end,             for releasably connecting to a corresponding mating             connector on the second member.

The key may be for a machineless, adhesiveless, and/or fastenerless releasable connecting of the first and second member.

The key may be made from a more resilient material than the material of the first and second members.

According to another embodiment, there is provided a furniture assembly comprising

-   -   at least a first and second member having mating connectors; and     -   a key having a substantially elongated body to releasably         connect the first and second member at a right angle, the body         having         -   a first mating connector on one end for releasably             connecting to a corresponding mating connector on the first             member; and         -   a second mating connector on a diametrically opposed end,             for releasably connecting to a corresponding mating             connector on the second member.

The first member may be a table top.

The second member may be a ground engaging means.

The ground engaging means may be a pedestal, or at least one leg.

According to another embodiment, there is provided a door assembly kit comprising:

-   -   at least one first member comprising         -   an interior face and an exterior face; and         -   at least one end having a mating connector; and     -   at least one second member comprising         -   an interior face and an exterior face; and         -   at least one end having a mating connector;     -   at least one key having a substantially elongated body to         releasably connect the first and second member at a right angle,         the body having         -   a first mating connector on one end for releasably             connecting to a corresponding mating connector on the first             member; and         -   a second mating connector on a diametrically opposed end,             for releasably connecting to a corresponding mating             connector on the second member     -   wherein the first and second members are releasably connected at         a right angle.

Each opposing ends of the second member may comprise a mating connector.

Three or four ends of the second member may comprise a mating connector.

The door assembly kit may further comprise at least one mating connector on another end of the first and second members and the first and second members form a frame assembly.

The frame assembly may be defining a center for receiving a third member.

The door assembly kit may further comprise a third member comprising

-   -   an interior face and an exterior face; and     -   at least one end having a mating connector for receiving a         corresponding mating connector of a key, wherein the key has         another mating connector for releasably connecting to a mating         connector on an adjacent first and second member.

Two, three or four ends of the third member may comprise a mating connector.

The door assembly kit may further comprise an implement.

The implement may be chosen from a handle, a lock, a sliding lock, and combination thereof.

The first member, second member or third member may further comprise an aperture.

According to another embodiment, there is provided a method to releasably assemble a first and second member at a right angle comprising:

-   -   releasably connecting at a right angle the first and second         member with a key comprising:         -   a substantially elongated body having             -   a first mating connector on one end for releasably                 connecting to a corresponding mating connector on the                 first member; and             -   a second mating connector on a diametrically opposed                 end, for releasably connecting to a corresponding mating                 connector on the second member.

The key may be for releasably connecting the first and second member by a person in a non-manufacturing facility.

The releasably connecting may be performed without a machine, an adhesive, and/or a fastener.

Features and advantages of the subject matter hereof will become more apparent in light of the following detailed description of selected embodiments, as illustrated in the accompanying figures. As will be realized, the subject matter disclosed and claimed is capable of modifications in various respects, all without departing from the scope of the claims. Accordingly, the drawings and the description are to be regarded as illustrative in nature, and not as restrictive and the full scope of the subject matter is set forth in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of the present disclosure will become apparent from the following detailed description, taken in combination with the appended drawings, in which:

FIG. 1 illustrates a perspective view of one embodiment of a portion of a door assembly according to the present invention.

FIG. 2 illustrates an exploded perspective view of one embodiment of a portion of a door assembly according to the present invention.

FIG. 3 illustrates an exploded perspective view of one embodiment of a portion of a door assembly according to the present invention.

FIG. 4 illustrates a cross-sectional view of one embodiment of a door assembly with a frame assembly according to the present invention.

FIG. 5A illustrates a front view of one embodiment of a door assembly forming a frame assembly according to the present invention.

FIG. 5B illustrates a front view of one embodiment of a door assembly forming a frame assembly according to the present invention.

FIG. 6 illustrates a perspective view of a key according to the present invention.

It will be noted that throughout the appended drawings, like features are identified by like reference numerals.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In embodiments there are disclosed building materials. More particularly, the embodiments relates to a key for releasably connecting members at a right angle, to door assembly kits and door and frame assembly kits. The door assembly kits of the present invention may be comprised of at least two members which are joined together through a mating connector. Preferably, the members may be rectangular, but they may also be square in shape. They may also be of shapes different than rectangular and square.

Referring now to the drawings, and more particularly to FIG. 6, there is shown an embodiment of a key, referred to as numeral 80, which may be used to releasably connect members at a right angle. They key may be used for releasably connecting members or parts of any type of furniture or door. The key 80 comprises a substantially elongated body having a first mating connector 82 is formed on one end and a second mating connector 84 is formed on another, diametrically opposed end. The mating connectors of the key may be used to releasably connect to corresponding mating connectors on first and second members and connect them at a right angle. The key 80 may be formed integrally as a single piece from one material, for example wood, metal or plastic, or according to another embodiment, it may be formed through the coupling of identical or different mating connectors. The key 80 may be of any suitable shape or form for releasably connecting members. It may also be of any suitable size or dimension, so that it may be used to releasably connect members of different sizes. According to one embodiment of the present invention, the key 80 may be used to connect members in a machineless, adhesiveless and/or fastenerless manner. Preferably, the key 80 is made from a material of a similar hardness or that is more resilient than the material of the first and second member. For example, the material of the key 80 and the first and second member could be the same wood, or a MDF material with similar characteristics. Most preferably, the key 80 is made from a material that is more resilient than the material of the members, such that when it is inserted in the respective mating connectors of the members, it may compress and form a tight fit between the mating connectors of the key and the members. For example, the key 80 could be prepared from pine wood, and the members could be prepared from oak.

According to another embodiment of the present invention, there is disclosed a furniture assembly which comprises first and second members having mating connectors, and at least one key 80 as described above. For example, the first member may be a table top or the likes, and the second member may be a ground engaging means such as pedestal, or one or more legs, to complete a table assembly. The key according to the present invention is used to releasably connect the table top and the pedestal or legs in a strong and firm manner, but nevertheless a releasable manner.

Referring now to the drawings, and more particularly to FIG. 1, there is shown an embodiment of a door assembly kit, generally referred to as numeral 10, and has one or more first member 20 comprising an interior face 22 (not shown) and an exterior face 24; and ends 26 and 28. Ends 26 (not shown) or 28 has a mating connector 30. Other ends of the first member may also have a mating connector. According to another embodiment of the present invention, two or three ends of the first member 20 may have a mating connector.

The door assembly kit also has one or more second member 40, also having an interior face 42 (not shown) and an exterior face 44; and two ends 46 and 48. At least one of the ends has a mating connector 50. The door assembly kit also comprises at least one key 80 as described above. They key's first and second mating connectors 82 and 84 may be inserted in the corresponding mating connectors 30 and 40, for releasably connecting the first member 20 to the second member 40 at a right angle, or to a mating connector on another second member, for example. Other ends of the second member may also have a mating connector. According to one embodiment of the present invention, the ends 46 and 48 of the second member, which are opposite one another, may each have a mating connector 50 (see FIG. 2). According to another embodiment of the present invention, two or three ends of the second member 40 may have a mating connector. According to yet another embodiment of the present invention, four ends of the second member 40 may comprise mating connector. As shown in FIG. 5A and B, according to another embodiment of the present invention, another end of the first and second members 20 and 40 may comprise another mating connector, and the first and second members 20 and 40 may form a frame assembly. The frame assembly defines a center where a third member may be inserted to complete an assembled door, or according to other embodiments, the center may also receive windows, glass panels, or panels of other materials such as Plexiglas™ or other plastic material, sheet screening and trellis.

Now referring to FIG. 3, according to another embodiment of the present invention, the door assembly kit may further include a third member 60 comprising an interior face 62 and an exterior face 64 and ends 66 and 68. At least one of the end (e.g. end 66) may have a mating connector 70 for receiving a corresponding mating connector 82 (or 84) of a key, which may be connected through the remaining mating connector 82 (or 84) to a mating connector 50 on the second member or a mating connector 40 on a first member 20 for releasably connecting the third member 60 to the adjacent first and second member(s) 20 and 40, respectively. Furthermore, when more than one third member 60 are coupled to second members 40 (in a columnar fashion), the superimposed third members 60 may also be joined to each other through mating connectors 70 present on their ends and a sufficient number of keys 80, as appropriate to complete the door. According to another embodiment of the present invention, two or three ends of the third member 60 may have a mating connector. According to yet another embodiment of the present invention, four ends of the third member 60 may comprise mating connector.

According to another embodiment of the present invention, any one of the first, second or third member 20, 40 or 60 may further have an aperture therein. The aperture may receive other wood panels, windows, glass panels, or panels of other materials such as Plexiglass or other plastic material, sheet screening and trelis.

Any one of the second and third member may receive implements such as for example door handle, locks, sliding lock, and combinations thereof.

Now referring to FIG. 4, according to one embodiment of the present invention, the door assembly may be hingely connected to a decorative frame assembly 90 which may be installed around an opening in a structure. The frame assembly 90 may be any conventional frame, and/or frames made from several portions and framing an opening in a structure.

According to another embodiment, there is disclosed a method to releasably assemble a first and second member at a right angle by releasably connecting the first and second member 30, 50 with a key 80 as described above. The key comprises a substantially elongated body having a first mating connector 82 on one end, for releasably connecting to a corresponding mating connector 30 on a first member 20; and a second mating connector 84 on a diametrically opposed end, for releasably connecting to a corresponding mating connector 50 on a second member 40. Upon assembly, the first and second member 30, 50 are connected at a right angle.

According to an embodiment of the present invention, key 80 may be used for releasably connecting members (e.g. first and second members 30, 50) by a person in a non-manufacturing facility, such as a household setting. According to yet another embodiment, said releasable connection between the members is performed without a machine, an adhesive, and/or a fastener.

In use, one may first select one or more first members. The selection may be according to predetermined decorative properties (e.g. wood grain or essence, varnish, paint color, design, engraving, embossing, etc), or physical properties (sturdiness, thickness, material (e.g. wood, metal, etc), or any properties desired. The first member, or combinations thereof may be sized and shaped according to standard door sizes. Secondly, one or more second members may be selected, again according to any of the desired properties. The second members or combinations thereof may also be sized and shaped according to standard door sizes. The second members may be compatible in size and shape with the first members so that a door is obtained once the members are assembled. According to another embodiment of the present invention, the second member(s) may also be of sizes, shapes and designs that allow intervening gaps in one or more portion of the door once assembly is complete. For example, one or more gaps could be filed in with glass panes (e.g. a window), wooden panes with identical or different finish or design, or the likes. Thirdly, one or more third members may be selected, again according to any of the desired properties. The third members or combinations thereof may also be sized and shaped according to standard door sizes so that a door is obtained once the members are assembled. The third members may be compatible in size and shape with the second members so that a door is obtained once the members are assembled.

In use, one may select the desired members by mixing and matching according to a desired pattern from pre-prepared or customized prepared members and create their own customized door assembly kit. According to another embodiment of the present invention, the door assembly kit may be purchased as a prepackaged unassembled door kit with members preselected according to a common or popular design. The members, or unassembled door assembly kit of the present invention may be purchased separately and conveniently carried in regular vehicle, forgoing the need of heavier or larger transportation that is normally required for delivery of fully assembled doors with or without attendant frames.

The door assembly kit of the present invention may be assembled by the purchaser with the use of a rubber mallet that is used to drive the provided keys and insert them in the mating connectors of the members, so as to create an assembled door therefrom. Furthermore, should a need arise to replace or change a member of the door, or an element of the assembled door such as a glass panel, the rubber mallet may be used to disassemble the door and perform a change or replacement.

While preferred embodiments have been described above and illustrated in the accompanying drawings, it will be evident to those skilled in the art that modifications may be made without departing from this disclosure. Such modifications are considered as possible variants comprised in the scope of the disclosure. 

1. A key for releasably connecting a first and second member at a right angle comprising: a substantially elongated body to releasably connect said first and second member at a right angle, said body having a first mating connector on one end for releasably connecting to a corresponding mating connector on said first member; and a second mating connector on a diametrically opposed end, for releasably connecting to a corresponding mating connector on said second member.
 2. The key of claim 1, wherein said key is for a machineless, adhesiveless, and/or fastenerless releasable connecting of said first and second member.
 3. The key of claim 1, wherein said key is made from a more resilient material than the material of the first and second members.
 4. The key of claim 1, wherein said key and said first and second members are made from a material with a similar hardness.
 5. A furniture assembly comprising at least a first and second member having mating connectors; and a key having a substantially elongated body to releasably connect said first and second member at a right angle, said body having a first mating connector on one end for releasably connecting to a corresponding mating connector on said first member; and a second mating connector on a diametrically opposed end, for releasably connecting to a corresponding mating connector on said second member.
 6. The furniture assembly according to claim 5, wherein said first member is a table top.
 7. The furniture assembly of claim 5, wherein said second member is a ground engaging means.
 8. The furniture assembly according to claim 7, wherein said ground engaging means is a pedestal, or at least one leg.
 9. A door assembly kit comprising: at least one first member comprising an interior face and an exterior face; and at least one end having a mating connector; and at least one second member comprising an interior face and an exterior face; and at least one end having a mating connector; at least one key having a substantially elongated body to releasably connect said first and second member at a right angle, said body having a first mating connector on one end for releasably connecting to a corresponding mating connector on said first member; and a second mating connector on a diametrically opposed end, for releasably connecting to a corresponding mating connector on said second member wherein said first and second members are releasably connected at a right angle.
 10. The door assembly kit as claimed in claim 9, wherein each opposing ends of said second member comprise a mating connector.
 11. The door assembly kit as claimed in claim 9, wherein three or four ends of said second member comprise a mating connector.
 12. The door assembly kit as claimed in claim 9, further comprising at least one mating connector on another end of said first and second members and wherein said first and second members form a frame assembly.
 13. The door assembly kit as claimed in claim 12, wherein said frame assembly is defining a center for receiving a third member.
 14. The door assembly kit as claimed in claim 9, further comprising a third member comprising an interior face and an exterior face; and at least one end having a mating connector for receiving a corresponding mating connector of a key, wherein said key has another mating connector for releasably connecting to a mating connector on an adjacent first and second member.
 15. The door assembly kit as claimed in claim 13, wherein two, three or four ends of said third member comprise a mating connector.
 16. The door assembly kit according to claim 9, further comprising an implement.
 17. The door assembly kit according to claim 11, wherein said implement is chosen from a handle, a lock, a sliding lock, and combination thereof.
 18. The door assembly kit according to claim 9, wherein any one of said first member, second member or third member further comprises an aperture.
 19. A method to releasably assemble a first and second member at a right angle comprising: releasably connecting at a right angle said first and second member with a key comprising: a substantially elongated body having a first mating connector on one end for releasably connecting to a corresponding mating connector on said first member; and a second mating connector on a diametrically opposed end, for releasably connecting to a corresponding mating connector on said second member.
 20. The method according to claim 19, wherein said key is for releasably connecting said first and second member by a person in a non-manufacturing facility.
 21. The method according to claim 19, wherein said releasably connecting is performed without a machine, an adhesive, and/or a fastener.
 22. The door assembly kit as claimed claim 14, wherein two, three or four ends of said third member comprise a mating connector.
 23. The door assembly kit according to claim 14, wherein any one of said first member, second member or third member further comprises an aperture. 